operating and installation instructions model: gel low

OPERATING AND INSTALLATION
INSTRUCTIONS
MODEL: GEL LOW TEMPERATURE
REMOTE ENDLESS
Hussmann – Gloversville
140 East State Street · Gloversville, New York 12078
(518)725-0644 – (800) 753-7790 – FAX (518) 725-3801
(518) 725-0661
TABLE OF CONTENTS
Page
1
1
1
1
1
Model Description
Application
Shipping Damage
Location
Clearance
Initial Set-Up Skid/Crating
Joining
Leveling
Exterior Loading
Door Adjustment
1
1-2
2
2
2
Drain Piping
Installation of Field Drain
Installation of Splash Guard
2
3
3
Refrigerant Types/Piping
Table for BTU Rating
Expansion Valve Adjustment
4
5
5
Refrigerant and Defrost Controls (Conventional Multiplexing)
Electrical Connections
Identification of Wiring
6
7
7
Koolgas Defrost
Light Switch
Humidstat Control
Electrical Specifications
Thermostats
7
7
8
8
8
Stocking & Stock Rotation
Up-Keep Care and Cleaning
9
9
Trouble Shooting Charts
Warranty Parts and Information
10/11
11/12
Electrical Components Replacement List
12
1
Introduction, Inspection,
Location & Clearance, Initial Set-up
Exterior Loading and Door Adjustment
MODEL DESCRIPTION LOCATION –
The GEL model is a remote, closed
type; glass door refrigerated merchandiser for
low temperature application. They are
available in 2, 3, 4, and 5 door versions.
It is good practice to avoid locating
the case where direct sunlight would shine
into the fixture for extended periods of time
or where drafts from air conditioning grilles,
fans, and open doors would blow into the case
when being used.
APPLICATION –
This refrigerated merchandiser has
been designed for use in air-conditioned
stores with temperatures of 75ºF and a
relative humidity of less than 55%.
Conditions other than these will reduce
cabinet efficiency and it is undesirable to run
the cabinets continuously under these adverse
conditions.
CLEARANCE –
A minimum four-inch clearance from
the back and ends of these models to walls,
shelving, and other refrigerators, etc., is
required to prevent sweating.
INITIAL SET-UP skid and crating –
This refrigerated merchandiser has
been designed for either frozen food (0ºF)
temperature or ice cream (-15º F)
temperatures.
The wood runners or skid and crating
should be left on the case until it is near its
final location. These give protection for both
case and floor.
SHIPPING DAMAGE –
JOINING –
All equipment should be thoroughly
examined for shipping damage before and
when unloading.
These merchandisers are of sectional
construction. Two or more may be joined in
line to give the affect of one continuous
display. To join, the following HussmannGloversville Kits with instructions included
are required:
If there is any damage, the carrier
should be notified immediately and an
inspection requested. The delivery receipt
must be noted that the equipment was
received damaged. If damage is of a
concealed nature, the carrier should be
notified immediately or no later that three
days following delivery. A CLAIM FOR
DAMAGES MUST BE FILED WITH THE
CARRIER BY THE CONSIGNEE.
♦ Joint Kit – Use when joining on
merchandiser to another
♦ Plexiglass Partition Kit – Use when
joining merchandisers that operate at
approximately the same temperatures, but
at different defrost cycles.
2
♦ Insulated Partition Kit – Use when
joining ice cream merchandisers to frozen
food merchandisers.
2. A single screw on top of the torquemaster
attaches the device to the door frame.
3. Tightening a screw on the side of the
Torquemaster corrects door fit when
necessary, squaring the door in its frame.
♦ End Assembly Kit – Use to close off the
open end of a line-up.
4. To adjust the torque, turn the screw on the
front counter-clockwise. Do not over
adjust torque to the point of slamming.
Caution: All joints must be airtight to
prevent formation of ice or condensation
between the merchandisers joined. The
merchandisers must be level and aligned to
insure proper match of joint trim.
LEVELING –
These merchandisers must be installed
level (front to back, end to end) to allow
proper draining of the defrost water and
operation of the doors.
EXTERIOR LOADING –
Caution the tops of these
merchandisers are not designed to support
excessive external loading such as the
weight of a person. Do not walk on these
merchandisers as damage and serious
personal injury could occur.
ARDCO DOOR ADJUSTMENT
Insert tool into adjusting nut at center
of door in the recessed location opposite the
electrical plug. Rotate tool in direction door
opens. Use sufficient force to overcome
prevailing torque locknut tension. Use
alternated end of tool (both are same) for
faster stroke adjustment.
DRAIN PIPING –
The cabinet is equipped with a 1.5”
IPS drain located under the center of the
cabinet approx. 10” in from the front edge.
Connections are made so field piping comes
straight towards the front and then piping can
go left or right towards either end of the case.
Access to clear the drain screen inside the
case is gained by opening a door towards the
center of the case, removing a bottom pan and
ANTHONY DOOR ADJUSTMENT
1. The torquemaster’s compact, unobtrusive
form is perfect for new units or retrofit.
One-device controls any size door and
hinge swing.
3
clearing the drain. This should be done with
power off since rotating fans are in the same
area.
2. Always provide as much downhill slop
(fall) as possible: 1/8 inch per foot is the
preferred minimum.
TO INSTALL FIELD DRAIN PIPING –
3. Avoid long runs of drainpipes, which
make it impossible to provide the “fall”
necessary for good drainage.
Connect field drain piping to water
seal.
4. Never use two water seals in series in any
one drainpipe. Double water seals will
cause an air lock and prevent draining.
5. Prevent drain pipes from freezing. Where
pipes are located in a cold air space,
provide means to prevent freezing.
6. Provide a suitable air break between rim
of floor drain and outlet of drain pipe.
NEVER install drain pipe in
contact with uninsulated suction
lines. Suction lines should be
insulated with a non-absorbent
insulation such as Armstrong’s
Armaflex.
Water Seal
INSTALLING SPLASHGUARD –
The splashguard and all the material
for its installation is shipped inside the case.
™ Assemble multiple piece splash guards
together with two screws at center joint.
Note orientation of parts so slots are
located at same side.
NOTE – Improperly installed drain piping
can seriously interfere with the operation
of the refrigerated equipment and result in
costly maintenance and product loss. We
recommend the following should be
followed when installing drain piping.
™ Slip top edge over top edge of ‘C’ type
bracket.
™ Push up bottom of splash guard so slots
drop onto bottom upturned tab of ‘C’ type
bracket.
1. Never use pipe smaller than the nominal
diameter of the pipe or water seal supplied
with the merchandiser.
4
™ At end of case, attach end piece of splash
guard with screws provided with optional
end kit.
screw end splash guard into end of
front splash with screws provided.
loosen bolt in rear of cabinet and slide rear
tab of splashguard between rear base rail
and bolt head
Screw together with
screws provided
(GEL/M –4 & 5)
C-bracket
Front Splashguard
INSTALLATION OF SPLASH GUARD
REFRIGERANT TYPES –
These connections are to be made at
the lower right hand front end (facing front)
of the case. Internal access is gained by
removing bottom pans behind the right hand
door. An access hole is provided for the lines
to exit through the bottom of the case.
These merchandisers will be supplied
for operation on R-404A refrigerant unless
otherwise specified on the Purchase Order.
See Serial Plate, located above the left-hand
door, for proper type refrigeration
REFRIGERANT PIPING –
Do not run refrigerant lines of
merchandisers connected to one condensing
unit or refrigeration system through those
connected to another condensing unit or
refrigeration system.
Refrigerant Line connections sizes –
Model
GEL-2,3,4, & 5
Liquid Line 3/8” OD
Suction Line 7/8” OD
There is room either behind the
splashguard to run refrigerant lines or run the
5
is required wherever condensation and
drippage would be objectionable.
lines out the backside of the cabinet because
of the recessed base.
Refrigerant lines should be sized as
shown on the refrigeration legend furnished
by the owner; if a legend has not been
furnished. Refer to Section 4 of the
Hussmann Application Engineering Manual.
Pressure Drop: Pressure drop can rob the
refrigeration system of capacity. To keep
pressure drop to a minimum use proper tubing
and keep the refrigeration line run as short as
possible using the minimum number of
elbows. Where elbows are needed, use long
radius elbows.
Piping Insulation: For models with “electric
defrost”, the suction and liquid lines should
be clamped or taped together and insulated for
a minimum of 30 feet. Additional insulation
for the balance of the liquid and suction lines
TABLE FOR BTU RATING
Cabinet
BTU/HR
EVAP
CAB.TEMP
AMBIENT
GEL-2
GEL-2
3620
3100
-14ºF
-22ºF
0ºF
-15ºF
75ºF
75ºF
GEL-3
GEL-3
4635
5430
-14ºF
-22ºF
0ºF
-15ºF
75ºF
75ºF
GEL-4
GEL-4
6180
7240
-14ºF
-22ºF
0ºF
-15ºF
75ºF
75ºF
GEL-5
GEL-5
7725
9050
-14ºF
-22ºF
0ºF
-15ºF
75ºF
75ºF
EXPANSION VALVE ADJUSTMENT –
securely taped to one of the return bends two
thirds of the through the evaporator circuit.
Some “hunting” of the expansion valve is
normal. The valve should be adjusted so that
during the hunting the greatest difference
between the two probes is 3º to 5ºF. Remove
valve stem cover and turn valve stem counterclockwise to decrease temperature difference
between the probes.
The expansion valve must be adjusted
to fully feed the evaporator. Before
attempting to adjust the valve make sure the
evaporator is either clean or only lightly
covered with frost, and that the cabinet is
within 10º of its expected operation
temperature. Adjust the expansion valve as
follows:
To increase temperature difference of
probes, turn the valve stem clockwise. With
this adjustment, during a portion of the
hunting the temperature differences between
Attach two sensing probes to the
evaporator, one under the clamp holding the
expansion valve sensing bulb and the other
6
Replace and tighten cover of the
valve stem.
the two probes may be less than 3ºF, or at
times as low as 0ºF. Make adjustments of no
more than one half turn of the valve stem at a
time and wait for at least fifteen minutes
before rechecking probe temperature and
making further adjustments.
REFRIGERATION AND DEFROST CONTROLS FOR
CONVENTIONAL MULTIPLEXING
Type of Control
Location
Refrigeration control
Low Pressure Control
Refrigeration Therm. (1)
On Condensing Unit
On cabinet as an option
Defrost Control
Temperature (2)
Terminated Type
On Condensing Unit
Defrost Thermostat
(3)
On Cabinet as Standard
Fan and Condensate (3)
On Cabinet as Standard
Alarm Heater (Defrost Limit)
Thermostat (4)
On Cabinet as Standard
Case Lighting Thermostat (4) On Cabinet as an option
If not using a low pressure control, an
optional refrigeration thermostat may be
employed. This would be factory installed
behind the cover on the left hand flue panel
on the back of the case. Cover can be
removed by removing two sheet metal screws.
This thermostat is a single pole double
throw bimetal switch factory installed on the
evaporator outlet tube. No field adjustment is
possible. Defrost is terminated at 59ºF. The
fans are delayed until the thermostat reaches
32ºF. For wiring more than one thermostat in
series or more than one merchandiser see
wiring diagram in Section IV.
Wires to the temperature control are
routed into the wire raceway at the lower left
hand front, through on of the PVC wire tubes.
Then run wires past L.H. end of evaporator
coil, through the air baffle and up the back of
the case to the temperature control.
This thermostat is a single pole double
throw bimetal switch factory installed on left
hand end of the inner liner top behind the
evaporator coil. No field adjustment is
possible. If defrosts starts and the timer
Supplied with condensing unit.
7
may be added, but adding more than 1 or
2 per day is not advisable.
fails, this stat prevents overheating of the case
(and product) by shutting off the defrost
heaters when it senses 100ºF.
Wiring Defrost Thermostats for Multiplex
Systems
ELECTRICAL CONNECTIONS –
All electrical connections are made at
the electrical terminal board located at the
lower front of the cabinets. Access is gained
by removing the lower bumper panel (with
sheet metal insert) by removing the
thumbscrews at the bottom of the panel.
Knockouts are provided for permanent field
wiring connections
The following is a suggested method
of wiring defrost thermostats in series to
maintain temperature termination and fan
delay.
When wiring the defrost system of
more than one cabinet to one defrost clock,
this clock should be set for at least a 45
minute failsafe. The defrost thermostats
should be wired in series but each separate
defrost thermostat will terminate the defrost
in that case. Defrost in all the cases will not
terminate until the last thermostat in series
senses the proper temperature and then
defrost will end and refrigeration will begin
again.
IDENTIFICATION WIRING –
All wiring is number coded and
labeled for proper voltage. Any green or
green with yellow stripe wire is for grounding
purposes. Consult the wiring diagram for
detailed wire connections.
The fans in each case will come on
when the proper temperature is sensed.
Defrost – Sequence of the Electric Defrost
1. When the timer initiates the defrost
period, the following occurs:
KOOLGAS DEFROST –
2. Compressor will stop and the defrost
heaters will energize.
Koolgas defrost is time initiated and
time terminated. Normally 20 minutes is
sufficient time but heavy humidity/usage may
require longer defrost times. The fans and
anti-condensate heaters are controlled by a
thermostat similar to the electric defrost
described above.
3. When defrost thermostat senses 58ºF the
defrost will terminate and the compressor
will start.
4. For a short time after defrost termination,
the fans and anti-condensate heaters will
remain off. They will come on when their
thermostat senses 32ºF.
LIGHT SWITCH –
The light switch is located inside and
above the door opening at the left hand end of
the case.
5. Normally, one defrost every 24 hours,
with the defrost failsafe set for 40 minutes
should b sufficient for proper defrost.
Ambient conditions, amount of store
traffic, and case loading can influence the
quantity of defrost required. Extra defrost
8
HUMIDSTAT CONTROL –
When optionally ordered, a humidstat control is factory installed in the electrical
raceway behind the front bumper panel. This system is wired into the frame and door-anticondensate heaters, as shown in the wiring diagram supplied with the case. For further
information and servicing, refer to the instruction manual furnished with the control.
ELECTRICAL SPECIFICATIONS –
CASE
ANTHONY DR
AMP.
(115 volt)
ea. total
ARDCO DR
AMP.
(115 volt)
ea.
total
GEL-2
GEL-3
GEL-4
GEL-5
1.02
1.02
1.02
1.02
1.04
1.04
1.04
1.04
2.04
3.06
4.08
5.1
LIGHT
AMP
(115 volt)
GEL-2
GEL-3
GEL-4
GEL-5
ARDCO FRAME
AMP.
(115 volt)
1.35
1.93
2.56
3.09
2.3
3.07
3.92
4.6
2.08
3.12
4.16
5.2
DEFROST
AMP
(208 volt)
2.0
2.9
3.7
4.3
ANTH FRAME
AMP.
(115 volt)
OPTIONAL
GLASS/END
AMP/END
(115 volt)
6.32
9.76
12.60
16.50
EVAP. FAN
AMP
(115 volt)
ea.
total
1.43
1.43
1.43
1.43
0.6
0.6
0.6
0.6
1.2
1.8
2.4
3.0
THERMOSTATS –
Defrost Thermostat
Normal Position
Fan Thermostat
Normal Positon
32ºF
58ºF
20ºF
35ºF
Defrost Heater Limit
Thermostat
Normal Position
101ºF
83ºF
BRN
RED
BLK
To Defrost Timer
BRN
RED
BLK
9
To Fans
INITIAL START-UP and LOADING
GENERAL UP-KEEP, CARE and CLEANING
OPERATION and MAINTENANCE
STOCKING AND STOCK ROTATION -
introduce water faster than the drain pipe
can carry it away.
All shelves of these models are
intended for displaying the product. Shelves
are designed for a maximum load of 200 lbs.
per shelf.
OPERATION AND MAINTENANCE
THERMOSTATIC EXPANSION VALVE
The shelves are adjustable on 1-inch
increments. Spacing of 12” is recommended
for most applications. The bottom shelf is
built with a protective lip.
Remove the left hand bottom pan to
make any adjustments to the valve.
Merchandise should not be placed in
the case for at least 24 hours after being put
on operation.
Each fan motor is fastened to a section
of the evaporator housing. The fan can be
disconnected electrically by disconnecting the
quick connects.
EVAPORATOR FAN MOTORS –
Since frozen food and ice cream are
perishable, the display should be rotated.
Each time an item is restocked, the last few
packages at the rear should be moved to the
very front. This will prevent pockets of
unrotated food.
DEFROST HEATERS –
¾ Disconnect power – disconnect
connections at the terminal board at lower
left end of case behind bumper panel.
¾ Remove defrost heater clips and remove
defrost heater.
When restocking, doors should not be
kept open longer than necessary or high
temperature, frost formation, and high energy
consumption can occur.
¾ Reassemble in reverse order.
UP-KEEP, CARE and CLEANING –
LAMP BALLAST – (s)
To insure good sanitation, appearance,
and minimum maintenance, these models
should be thoroughly cleaned and washed on
a regular schedule.
Disconnect power – ballasts are
located in the mullions between doors. Refer
to Anthony’s instructions supplied with case
for removal and wiring.
All power supply to the case should be
shut off. Remove debris caused by broken
packages, torn wrappers, etc., before washing
since such foreign matter can clod the drain
pipe. Do not use abrasive cleaner or steel
wool as these will mar the finish. Never
FLUORESCENT LAMPS –
Note: Lamps are enclosed in optical lenses to
insure maximum lamp brightness and
protection against lamp breakage.
10
To Service Lamps:
DOOR & FRAME HEATERS –
¾ Remove lenses by removing metal
clamps, following Anthony’s instructions
provided with case.
For information concerning door
heaters, etc., see the door instructions
supplied with this booklet.
¾ Push up on lamp and rotate bottom out
towards door opening and remove.
¾ Reverse procedure to reinstall.
TROUBLE SHOOTING CHART
SYMPTOM
Warm storage temperature
PROBABLE CAUSE (S)
1. Temperature control not set
properly
2. Short of refrigerant
3. Cabinet location too warm
4. Refrigerant over charge
5. Low voltage, fans operating
at too low a speed
Icing condition
Drain area
1. Low voltage
2. Cabinet not level
3. Defrost heater (s) not
working
11
POSSIBLE SOLUTION (S)
1. Reset control
2. Leak check, evacuate and
recharge to condensing unit
instructions.
3. Correct excessive hat
source or relocate cabinet to
cooler location
4. Same steps as for short
refrigerant #2.
Check voltage at fans, should
not be more than 5% below
rating.
1. Check voltage at terminal
board
2. Check leveling and correct
3. Check connections and/or
replace heater
TROUBLE SHOOTING LIGHTING SYSTEM
PROBLEM
SOLUTION
Lights won’t start
1. Check light switch
2. Check continuity to ballast
3. Check to see if bulbs inserted properly into
sockets
4. Check voltage
Lights flicker
1. Allow lamps to warm up
2. Check lamp sleeve for cracks
3. Check sockets for moisture and proper
contact
4. Bulb replacement may be necessary
5. Check voltage
6. New bulbs tend to flicker until used
Ballast hums
1. Check voltage
2. Replace ballast
WARRANTY AND PARTS INFORMATION
Please read carefully to assure prompt and accurate service
ORDERING REPLACEMENT PARTS –
9 Contact your nearest Hussmann Distributor
9 Always specify model and serial number of cabinet
9 If correct part number is not known, give a clear description of part itself and its function in
the cabinet or remote unit
WARRANTY PARTS PROCEDURE
9 Same as the 3 items above
9 Give original installation date of cabinet and, if possible, forward a copy of the original
invoice or delivery receipt.
9 All shipments of in-warranty replacement parts will be invoiced from the factory until such
time as the defective part is returned and proved to be defective by our Quality Control
Department.
12
9 Contact your Hussmann Distributor for instructions on returning in-warranty parts.
9 Warranty parts must be returned to the factory within 30 days of date of failure to assure
proper disposition.
9 Lack of any of the above information may result in the shipment of the wrong part, or a delay
in shipment.
ELECTRICAL COMPONENTS REPLACEMENT LIST
Fan Blades
Fan Motors
Morrill
Emerson
G.E.
SP-B9HUBV16
FA33HXDL-164
5KSM51ECG3799A
Thorgren 8CW34
Relays
Defrost Thermostat
Aromat JAIB-TM-AC220-P
Aromat JAIC-TM-AC115-P
Thermo-Dis 14T 33 Style 27442
Fan Heater Thermostat
Ballast
Lamps
T.I. #20425D
1 lamp Anthony AE-15614
2 lamp Anthony AE-15624
Sylvania FO40/841
Optical Lens
AE-72419 (2) on mullions, (1) on end
13